Hi-Pressure Seal Models:
1. Lubricate seal chamber in manifold.
NOTE: For certain applications apply liquid gasket to
the O-Ring crevices and seal surfaces (refer to Tech
Bulletin 053).
2. Carefully square Hi-Pressure Seal into position by hand
with the grooved side down (metal back facing out).
NOTE: When alternate materials, the fit of the
special materials may be snug and require gently driv-
ing the LPS into position with a cylinder of the same
diameter to assure a square seating and no damage to
the LPS.
3. Examine Seal Case O-Ring and replace if worn. Lubricate
new O-Ring before installing.
4. Secure Hi-Pressure Seal into position by threading Seal
Case into manifold. Tighten Seal Case with special seal
case tool. Torque per chart.
Lo-Pressure Seal - All Models:
1. Examine Lo-Pressure Seals for wear or broken springs
and replace if necessary.
2. Install Lo-Pressure Seal into each seal case with garter
spring down.
3. On 5PFR and 7PFR plunger pumps do not use Snap Ring
(refer to Tech Bulletin 054).
4. On 15PFR plunger pumps install Snap Ring into each
Seal Case.
5. Install the Seal Retainer with new Wick onto each plunger
rod with tab down and wick out.
6. Rotate Crankshaft by hand so the two outside plungers
are extended equally.
7. Lightly lubricate the Ceramic Plunger, then carefully slide
the Manifold Head over the Ceramic Plunger, supporting it
from the underside to avoid damage to the plungers or
seals. Press the Manifold Head into the Crankcase until
flush.
8. Replace two (2) Lockwashers, two (2) Socket Head
Screws for (4) Flange Nuts and torque per chart.
SERVICING THE PLUNGERS
Disassembly
1. Using an M8 allen wrench on the 5PFR pumps, a M14 hex
tool on the 7PFR pumps, or a M17 hex tool on the 15PFR
pumps, remove the two (2) Socket Head Screws, and two
(2) Lockwashers or four (4) Flanged Nuts.
2. Rotate Crankshaft by hand to start separation of Manifold
head from Crankcase.
3. Insert two flat head screwdrivers on opposite sides to further
separate Manifold Head from Crankcase or support the
underside of the Manifold Head and tap lightly with a mallet
on the backside of the Manifold Head.
CAUTION: KEEP MANIFOLD PROPERLY ALIGNED
WITH CERAMIC PLUNGERS WHEN REMOVING TO
AVOID DAMAGE TO EITHER PLUNGERS OR SEALS.
4. Remove Oil Pan and slide out Seal Retainer with Wick.
5. Using an M12 hex tool on the 5, 7 and 15PFR pumps, or
an M11 hex tool on the OEM 5, and 7PFR pumps, loosen
the Plunger Retainer about three to four turns.
6. Push the Ceramic Plunger back towards the Crankcase to
separate it from the Plunger Retainer and proceed with un-
threading the Plunger Retainer by hand.
7. Remove the Plunger Retainer, O-Ring, Back-up-Ring and
Gasket. Stud may stay on Plunger Rod or come off with
Plunger Retainers.
8. Remove the Ceramic Plunger, Keyhole Washer and
Barrier Slinger from Plunger Rod.
Reassembly
1. Visually inspect Crankcase Oil Seals for deterioration or
leaks. Contact CAT PUMPS for assistance with replace-
ment. See SERVICING THE CRANKCASE section.
2. Examine Barrier Slingers and Keyhole Washers for dam-
age. Slide onto Plunger Rod with concave side away
from Crankcase.
3. Examine Ceramic Plunger for scoring, scale build-up, chips
or cracks and replace as needed.
4. Slide Ceramic Plunger over each Plunger Rod.
NOTE: Ceramic Plunger can only be installed in one
direction (front to back). Do not force onto rod.
5. Examine O-Ring and Back-up-Ring on Plunger Retainer
and replace if cut or worn. Lubricate O-Rings for ease of
installation and to avoid damage to the O-Rings.
Ceramic Plunger and Retainer Arrangement
Proper Alignment of Ceramic Plungers for reassembly
